Process Control Instrumentation Research Articles

Need Based Design and Topology of Power Supply for Industrial Instruments

Abstract: Process control instruments plays decisive role in regulation and monitoring like control actions which requires efficient circuit analysis and different input and output power supplies to make it connectable in panels or used separately. This paper gives a comprehensive study of power supply used in instruments, based on power electronics principle used to improve circuit performance. Furthermore, it also includes analysis for energy conversion, switching devices, control methods, conduction modes and protection mechanism to make the supply efficient. Supply topologies i.e., Linear& Switched Mode Power supply are used as per the requirement of instruments. Both the supplies include different challenges and solutions to overcome losses and make the supply efficient. The analysis includes various parameters like voltage, current, power loss, waveform, efficiency, switching, feed-back and ringing. These parameters affect the whole supply if problem occurs in any of them.

In-cavity pressure measurements for failure diagnosis in the injection moulding process and correlation with numerical simulation

The pressure profile analysis for monitoring and diagnosis processing failures during an injection moulding process, such as burn marks and short shots, is a useful instrument for process and part quality control and production with zero defects and greater efficiency. Therefore, this work aims to demonstrate the in-cavity pressure monitoring feasibility for failure diagnosis and injection moulding process optimization. The methodology used to analyse the obtained pressure variation is presented. The results were correlated to the typical cavity pressure profile, which enables the acquisition of information about the process and the moulding tool. This way, it was possible to determine the origin of the defects present in the injected parts, focusing not only on the velocity to pressure switchover but also on the initial part of the curve, related to the filling phase. Moreover, the obtained results and the studied processing conditions were correlated with the injection moulding process simulation.

Saving the environment by automation of crude oil distillation in a rectification column

The article shows the results of the development of an automated control system for the distillation of oil in a distillation column, which makes it possible to save the environment. In the theoretical part, the process of distillation of crude oil in a distillation column is described and its technological scheme is given for atmospheric distillation with a single evaporation of oil. In the calculation part, the heat and material balance of mass transfer in the rectification column has been analyzed. In the practical part, the problems of installing process control instruments, improving the emergency shutdown system reliability, expanding the automatic and automated monitoring and control functions, and improving the process control and facility performance analysis quality have been solved. The authors used the Trace Mode 6 software package to develop the SCADA of the distillation column control system. In conclusion, it was noted that the development and implementation of an automated control system for the oil distillation process provides an increase in plant productivity, as well as the quality and reliability of the process, which in turn has a positive effect on environmental conservation.

Working, design issues and applications of wireless sensor network

Wireless sensor networks (WSN) also known as wireless sensor and actuator networks (WSAN). These are distributed autonomous sensors for monitoring environmental or physical conditions, like sound, temperature pressure, etc. and used for passing their data via the network to a main location. These are measurement tools which are equipped with transmitters for converting the signals into a radio transmission from process control instruments. Receiver interprets the radio signal after that converts the wireless signal to a desired or specific output, like a data or Analog current analysis via computer software.

Performance of new nonparametric Tukey modified exponentially weighted moving average-Moving average control chart.

Control charts are an amazing and essential statistical process control (SPC) instrument that is commonly used in monitoring systems to detect a specific defect in the procedure. The mixed Tukey modified exponentially weighted moving average - moving average control chart (MMEM-TCC) with motivation detection ability for fewer shifts in the process mean under symmetric and non-symmetric distributions is proposed in this paper. Average run length (ARL), standard deviation of run length (SDRL), and median run length (MRL) were used as efficiency criteria in the Monte Carlo simulation, and their efficiency was compared to existing control charts. Furthermore, the expected ARL (EARL) is a method for evaluating the performance of control charts beyond a specific range of shift sizes. The distinguishing feature of the proposed chart is that it performs efficiently in detecting small to moderate shifts. There are applications for PM 2.5 and PM 10 data that demonstrate the performance of the proposed chart.

Design and development of a PWA - Progressive Web Application, to consult the diary and programming of a technological event

Expotecnología is an event aimed at students, teachers and professionals in the areas of systems, computing, petrochemicals, process control and industrial instrumentation, electronics and telecommunications, electricity, electromechanics and civil works, with the purpose of addressing not only the challenges that accompany the various activities in which related professionals perform, but also the problems, projects and programs of the academic units in which they are trained. In addition, it is a conducive space to enhance their role in the profession, research and academy. Currently, there is a website for the Expotecnología event, which can be seen here: https://expotecnologia.unitecnar.edu.co. But all the scheduling and schedule management is consulted manually by means of flyers, billboards or email. In this sense, it is necessary to develop a progressive web application, where all the optimized processes can be carried out, in addition the participants to the event would not have any inconvenience to know the day, time and place where they will be presented, because it can also work without internet connection (offline).

Reconfigurable Flow Platform for Automated Reagent Screening and Autonomous Optimization for Bioinspired Lignans Synthesis.

Naturally occurring benzoxanthenones, which belong to the vast family of lignans, are promising biologically relevant targets. They are biosynthetically produced by the oxidative dimerization of 2-propenyl phenols. In this manuscript, we disclose a powerful automated flow-based strategy for identifying and optimizing a cobalt-catalyzed oxidizing system for the bioinspired dimerization of 2-propenyl phenols. We designed a reconfigurable flow reactor associating online monitoring and process control instrumentation. Our machine was first configured as an automated screening platform to evaluate a matrix of 4 catalysts (plus the blank) and 5 oxidants (plus the blank) at two different temperatures, resulting in an array of 50 reactions. The automated screening was conducted on micromole scale at a rate of one fully characterized reaction every 26 min. After having identified the most promising cobalt-catalyzed oxidizing system, the automated screening platform was straightforwardly reconfigured to an autonomous self-optimizing flow reactor by implementation of an optimization algorithm in the closed-loop system. The optimization campaign allowed the determination of very effective experimental conditions in a limited number of experiments, which allowed us to prepare the natural products carpanone and polemannone B as well as synthetic analogues.

STUDENTS BUILDING DIDACTIC EXPERIMENTS AS A TOOL FOR TEACHING UNIT OPERATIONS AND PROCESS CONTROL FOR CHEMISTRY TECHNICIANS

The qualified preparation of technician chemistry students who will act directly in the operation and control of industrial chemical plants is a permanent challenge in the teaching-learning process, since such activities require a broad view of the process and a sum of knowledge’s areas such as unit operations, instrumentation and industrial process control. An alternative to better understand these chemical engineering subjects within the technician chemistry course is the use of didactic experiments, which aims to provide an approximation of the taught content in the classroom with practical operation in a dynamic way, facilitating the teaching-learning process. In this sense, this work aimed to propose to the students of the technician chemistry course integrated to high school to use their creativity, combined with the technical concepts studied in the classroom, to build didactic experiments of unit operations within the following topics: heat exchanger, adsorption, humidification and drying. The results were evaluated in the form of performance technical data and qualitative questionnaire. Results have evidenced the positive character in the teaching-learning process of the operating principles of the unit operations, besides allowing the students a direct contact with process control and industrial instrumentation.

Dilatometry Coupled with Mass Spectrometry as Instrument for Process Control in Sintering of Powder Metallurgy Steels

The production of ferrous powder metallurgical parts by the press-and-sinter route becomes more and more attractive. Today, parts are produced for loading requirements that until now only could be fulfilled by conventional produced steel components. The high mechanical properties that must be attained require the use of alloying elements so far not common in powder metallurgy because of their high affinity for oxygen. The sintering of chromium containing steels is a challenge for the whole production process, because the reduction of the surface oxides is critical for successful sintering.Dilatometry can be a useful instrument to control the sintering behaviour of the materials, especially the combination with mass spectrometry allows analysing the very complex sintering process and simultaneously monitoring the solid-gas reactions. This work shows that the sintering atmosphere plays a major role in the entire process. Degassing and deoxidation processes during sintering are demonstrated for different alloying systems (Fe, Fe-C, Fe-Mo-C, Fe-Cr-Mo-C). Dilatometry coupled with MS is shown to be a very good instrument for process control of the sintering process. The generated analytical data can be related to the mechanical properties of the sintered steels if the size of the specimen is large enough.

Determining the Gross Efficiency of a Boiler in Real Time

Atechnique for the continuous automatic determination of the gross efficiency of a boiler from the readings of regular process-control instruments was developed and implemented at a CHPP. The possibility of saving fuel by controlling the efficiency of the boiler in real time is discussed.

Direct Digital Control

With the advent of digital computers the engineers felt the need of utilizing computer advantages in the industrial process through the centralized control system. This thought led to the introduction of direct digital control (DDC) phylisophy. In this paper the author has presented a brief review of the structure of DDC as well as its working with illustration. The two types of algorithm used for programming as PID controller are discussed. The author has also pointed out the merits of DDC over analog control.Besides a few practical application has also been described. With the introduction of computers, engineers felt the need of utilizing computer advantages in instrumentation field through centralized control system. These advantages were optimization, alarm and logging function, historic analysis, trending, sequence control and self diagnostic techniques. This gave birth to Direct Digital phylisophy in instrumentation with a back up of analog control system. In 1962, Imperial Chemical Industries (ICI) in England replaced complete analog instrumentation for process control by a Ferranti Argus computer. The computer considered 224 variables and controlled 129 valves directly. The name direct digital control (DDC) was coined to emphasize that the computer directly controlled the processes. DDC i.e. Direct Digital is a method of process control in which computer is an integral part of the loop. It essentially consists of microprocessor / pc / computer based controllers and the control logic is performed by software. It is also known as Loop Control as the computer which provides the functions of cmparator, controller, limiting and other safeguarding operations, is conneted in the feedback loop.

Mining Process and Product Information From Pressure Fluctuations Within a Fuel Particle Coater

The next generation nuclear power/advanced gas reactor (NGNP/AGR) fuel development and qualification program included the design, installation, and testing of a 6-in. diameter nuclear fuel particle coater to demonstrate quality tri-structural isotropic (TRISO) fuel production on a small industrial scale. Scale-up from the laboratory-scale coater faced challenges associated with an increase in the kernel charge mass, kernel diameter, and a redesign of the gas distributor to achieve adequate fluidization throughout the deposition of the four TRISO coating layers. TRISO coatings are applied at very high temperatures in atmospheres of dense particulate clouds, corrosive gases, and hydrogen concentrations over 45% by volume. The severe environment, stringent product and process requirements, and the fragility of partially-formed coatings limit the insertion of probes or instruments into the coater vessel during operation. Pressure instrumentation were installed on the gas inlet line and exhaust line of the 6-in. coater to monitor the bed differential pressure and internal pressure fluctuations emanating from the fuel bed as a result of bed and gas “bubble” movements. These instruments are external to the particle bed and provide a glimpse into the dynamics of fuel particle bed during the coating process and data that could be used to help ascertain the adequacy of fluidization and, potentially, the dominant fluidization regimes. Pressure fluctuation and differential pressure data are not presently useful as process control instruments, but data suggest a link between the pressure signal structure and some measurable product attributes that could be exploited to get an early estimate of the attribute values.

Differenzierung der Codierqualität in der Orthopädie durch spezielle abbildungsorientierte Fallgruppenanalyse im G-DRG-System 2005

We introduce a grouping system for clinical practice which allows the separation of DRG coding in specific orthopaedic groups based on anatomic regions, operative procedures, therapeutic interventions and morbidity equivalent diagnosis groups. With this, a differentiated aim-oriented analysis of illustrated internal DRG data becomes possible. The group-specific difference of the coding quality between the DRG groups following primary coding by the orthopaedic surgeon and final coding by the medical controlling is analysed. In a consecutive series of 1600 patients parallel documentation and group-specific comparison of the relevant DRG parameters were carried out in every case after primary and final coding. Analysing the group-specific share in the additional CaseMix coding, the group "spine surgery" dominated, closely followed by the groups "arthroplasty" and "surgery due to infection, tumours, diabetes". Altogether, additional cost-weight-relevant coding was necessary most frequently in the latter group (84%), followed by group "spine surgery" (65%). In DRGs representing conservative orthopaedic treatment documented procedures had nearly no influence on the cost weight. The introduced system of case group analysis in internal DRG documentation can lead to the detection of specific problems in primary coding and cost-weight relevant changes of the case mix. As an instrument for internal process control in the orthopaedic field, it can serve as a communicative interface between an economically oriented classification of the hospital performance and a specific problem solution of the medical staff involved in the department management.

Oral History in Instrument and Control Engineering Dr. Hiro Yamasaki; Development of Process Control Instruments in Japan

Oral History in Instrument and Control Engineering Dr. Hiro Yamasaki; Development of Process Control Instruments in Japan

Controlling the thickness of a fluoroplastic coating for polyimide films

The order of developing instruments for process control proposed in [3] was confirmed on a concrete example. The ITP-1 instrument allows controlling the thickness of a fluoroplastic coating on a polyimide film directly in process equipment by a contactless method of measurement. The technical solutions for controlling the thickness of film and fibre materials when the object measured exhibits transverse mechanical oscillations are reported. A method is proposed for checking the ITP-1 instrument using a calculation equation. A possible area of application of these process solutions is indicated.

Compact ADC DAC Interface for Parallel Port

In the modern world of electronics and process control instrumentation, computers are used for automation and to achieve high speed and accuracy. Hence it is required to have a simple, efficient and reliable interface, which can establish the connection between analog and digital world. In this paper, we have discussed the design and fabrication of such an interface card. This card can be plugged into readily available parallel port of PC. The samples of analog signal can be obtained through this card and processed samples can be converted back into analog form using the DAC available on the card. This design makes use of readily available low cost ICs. The signal processing software can be developed using any of the commercially available high level software languages like C++, VB and VC etc. For the specialized applications, software like MATLAB can also be used along with this card. This card can also be used for instrumentation and control applications like implementation of PID controller etc.

Ultrasonic flowmeters: Half-century progress report, 1955–2005

Ultrasonic flowmeters are one of the fastest-growing technologies within the general field of instruments for process monitoring, measurement and control. Today, acoustic/ultrasonic flowmeters utilize clamp-on and wetted transducers, single and multiple paths, paths on and off the diameter, passive and active principles, contrapropagating transmission, reflection (Doppler), tag correlation, vortex shedding, liquid level sensing of open channel flow or flow in partially-full conduits, and other interactions. Ultrasonic flowmeters are applicable to liquids, gases, and multiphase mixtures, but not without limits. However, no single technology, nor one type of interaction within a technology, can be best for all fluids, occasions and situations. Users who select a particular type of ultrasonic flowmeter over one based on a competing (nonultrasonic) technology often do so for one (or more) of the following reasons: ultrasonic equipment provides a useful measurement whether the fluid is single-phase or not single-phase; equipment is easy to use; flow regime can be laminar, transitional or turbulent; transducers are totally external (no penetration of the pressure boundary); transducers, if not clamp-on, are minimally invasive; no excess pressure drop; when certain conditions are met, accuracy can be better than 0.5%; fast (ms) response; reliable despite temperature extremes; reasonable purchase price, installation, operating and maintenance costs. Sometimes mass flowrate is obtainable. Energy flowrate might be achieved for natural gas and biogas in the near future. How did ultrasonic flowmeters advance in the past fifty years to support such claims? This paper tries to answer this question by looking at ultrasonic flowmeter inventions and publications since 1955, to see how four key problems were solved.

Report by the analytical methods committee: evaluation of analytical instrumentation Part XXI NIR instrumentation for process control

Report by the analytical methods committee: evaluation of analytical instrumentation Part XXI NIR instrumentation for process control

Simple Model of Metal Oxide Varistor for Pspice Simulation

Metal oxide varistors (MOVs) are commonly used to suppress transients in many applications, such as industrial process measurement and control instrumentation, when exposed to electromagnetic interference. Varistors symmetrical, sharp breakdown characteristics enable them to provide transient suppression performance. A simple model of MOVs for Pspice simulation is proposed in this paper. The comparison between measured characteristics of MOVs and the proposed model results in a good approach for the active zone of the device. Besides, the comparison with other models shows that: 1) this one solves problems of numerical convergence and 2) there is an important reduction in the number of model parameters to be set beforehand.

Applied technology and instrumentation for process control

Applied technology and instrumentation for process control